Hybrid armor assembly

ABSTRACT

An armor assembly has a metal strike face with a front and a back. A textile is coupled to the front of the metal strike face, and a backer is coupled to the back of the metal strike face. A front cover is coupled to the textile, and a back cover is coupled to the backer. In addition, the metal strike face can allow a Level III or a Level IV projectile to penetrate the metal strike face and be stopped by the backer.

This application claims priority to and the benefit of U.S. Prov. Pat. App. No. 63/297,911, filed Jan. 10, 2022, and U.S. Prov. Pat. App. No. 63/351,636, filed Jun. 13, 2022, each of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to armor and, in particular, to a system, method and apparatus for hybrid armor.

BACKGROUND

Conventional armor is typically provided in many different configurations for many different applications. There is a need for an armor that can be repeatably hit and abused like current steel-based solutions, and yet be lightweight like current ceramic-based solutions. Accordingly, improvements in armor continue to be of interest.

SUMMARY

Embodiments of hybrid armor are disclosed. For example, an armor assembly can include a metal strike face comprising a front and a back. A textile can be coupled to the front of the metal strike face. A backer can be coupled to the back of the metal strike face. A front cover can be coupled to the textile, and a back cover can be coupled to the backer. In addition, the metal strike face can be configured to allow a Level III or a Level IV projectile to penetrate the metal strike face and be stopped by the backer.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features and advantages of the embodiments are attained and can be understood in more detail, a more particular description can be had by reference to the embodiments that are illustrated in the appended drawings. However, the drawings illustrate only some embodiments and are not to be considered limiting in scope since there can be other equally effective embodiments.

It shall be noted that some of the details and/or features shown in the drawings herein may not be drawn to scale for clarity purposes.

FIG. 1 is a front view of an embodiment of armor.

FIG. 2 is a top view of the armor of FIG. 1 .

FIG. 3 is a sectional side view of the armor of FIG. 1 taken along the line 3-3 of FIG. 1 .

FIG. 4 is an exploded side view of the armor of FIG. 1 .

FIG. 5 is a front view of an embodiment of a wrap for fragmentation prevention, shown in an open and unassembled configuration.

FIG. 6 is a side view of the wrap of FIG. 5 .

FIG. 7 is a rear isometric view of the wrap of FIG. 5 , shown in a closed and assembled configuration.

FIG. 8 is a rear view of the wrap of FIG. 7 .

FIG. 9 is a top view of the wrap of FIG. 7 .

FIG. 10 is a side view of the wrap of FIG. 7 .

FIG. 11 is a front view of another embodiment of armor.

FIG. 12 is a top view of the armor of FIG. 11 .

FIG. 13 is a sectional side view of the armor of FIG. 11 taken along the line 13-13 of FIG. 11 .

FIG. 14 is an exploded side view of the armor of FIG. 11 .

FIG. 15 is a front view of another embodiment of a wrap for fragmentation prevention, shown in an open and unassembled configuration.

FIG. 16 is a side view of the wrap of FIG. 15 .

FIG. 17 is a sectional side view of the wrap of FIG. 15 , taken along the line 17-17 of FIG. 15 .

FIGS. 18-20 are sequential side views of the wrap of FIGS. 15-17 transitioning from the open and unassembled configuration to a closing configuration, such as for the embodiment of armor depicted in FIGS. 11-14 .

FIG. 21 is a front view of the wrap of FIGS. 15-20 in a closed or assembled configuration.

FIG. 22 is a top view of the wrap of FIG. 21 .

FIG. 23 is a side view of the wrap of FIG. 21 .

FIG. 24 is a rear view of the wrap of FIG. 21 .

FIG. 25 is a sectional side view of the wrap of FIG. 24 , taken along the line 25-25 of FIG. 24 .

FIG. 26 is a sectional top view of the wrap of FIG. 24 , taken along the line 26-26 of FIG. 24 .

FIG. 27 is a front view of still another embodiment of armor.

FIG. 28 is a top view of the armor of FIG. 27 .

FIG. 29 is a sectional side view of the armor of FIG. 27 taken along the line 29-29 of FIG. 27 .

FIG. 30 is an enlarged sectional side view of an upper portion of the armor of FIG. 29 .

FIG. 31 is an exploded side view of the armor of FIG. 27 .

FIG. 32 is a front view of still another embodiment of armor.

FIG. 33 is a top view of the armor of FIG. 32 .

FIG. 34 is an enlarged partial front view of an embodiment of a strike face.

FIG. 35 is an exploded side view of the armor of FIG. 32 .

The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION

The following discussion is directed to various embodiments of the present disclosure. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to imply that the scope of the disclosure, including the claims, is limited to that embodiment. Accordingly, various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present disclosure. For example, while the embodiments described below refer to particular features, the scope of this disclosure also includes embodiments having different combinations of features and embodiments that may not include all of the below described features.

Referring to FIGS. 1-35 , embodiments of armor and wrap are disclosed. For example, FIGS. 1-4 depict an embodiment of a single curve armor assembly 101. FIGS. 5-10 depict an embodiment of a tensional wrap 151 for fragmentation prevention, such as for the armor assembly 101. FIGS. 11-14 depict an embodiment of a multiple curve (e.g., five curve) armor assembly 201. FIGS. 15-24 depict an embodiment of the textile 209 as a tensional wrap 209 for fragmentation prevention, such as for the armor assembly 201. In addition, FIGS. 27-31 depict an embodiment of an integrally pressed armor assembly 301. Details of each of these embodiment follow below. Whatever is described for any one of the embodiments of armor assemblies 101, 201 or 301 can be used in the other embodiments, whether identical or similar in nature.

Single Curve Armor

Versions of the armor assembly 101 can include a metal strike face 103 comprising a front 105 and a back 107. A textile 109 can be coupled to the front 105 of the metal strike face 103. A backer 111 can be coupled to the back 107 of the metal strike face 103. In addition, a front cover 113 coupled to the textile 109, and a back cover 115 can be coupled to the backer 111. In some examples, the metal strike face 103 is configured to allow a Level III or a Level IV projectile to penetrate the metal strike face 103 and be stopped by the backer 111. The metal strike face 103 can be configured to augment a Level III or IV projectile and the backer 111 can stop the Level III and or level IV projectile.

In addition, the armor assembly can include a structural adhesive 121 to bond at least one of metal strike face 103, textile 109, backer 111, front cover 113 and back cover 115. The structural adhesive 121 can comprise structural epoxy and can, for example, have a thickness in a range of about 0.010 inches+/−0.01 inches. The structural adhesive 121 can comprise more than one type of adhesive. For example, at least one structural adhesive 121 can comprise a low energy bond, hi-strength acrylic adhesive.

In some versions, a backface reduction material 123 also may be coupled to the back 107 of the metal strike face 103. The backface reduction material 123 can comprise monolithic padding, structured padding, a type of foam or still other industry standard materials as is known in the art.

Embodiments of the metal strike face 103 can comprise at least one of heat-treated alloy, titanium, stainless steel, abrasion resistant steel, ballistic metal or ballistic alloy. In a direction normal to the metal strike face 103, the metal strike face 103 can have a thickness in a range of about 0.089 inches to about 0.5 inches. Versions of the metal strike face 103 can comprise an abrasion metal resistance, such as in a range of about 450 to about 2000 Vickers, or about 500 to about 1000 Vickers, or about 595 to about 674 Vickers. In addition, the metal strike face 103 can be configured to stop penetration of a Level I or Level II projectile through the metal strike face 103.

Any of the embodiments of the armor assemblies disclosed herein, including armor assembly 103, can further comprise a second strike face 403 (see, e.g., FIGS. 32-35 ) in another embodiment of an armor assembly 401. The second strike face 403 can be spaced apart from and coupled to the metal strike face 103. For example, the second strike face 403 can comprise at least one of a metal, an alloy or a ceramic. Embodiments of the backer 111 can be located between the metal strike face 103 and the second strike face 403, or behind the second strike face 403, as shown.

Embodiments of the textile 109 can comprise at least one of woven aramid or polyethylene. Examples of the backer 111 can comprise at least one of a textile, E-glass, R-glass, S-glass, polyethylene, polypropylene, polymer resin or aramid. Other examples of the backer 111 can comprise an ultra-high molecular weight polyethylene (UHMWPE). Versions of the backer 111 can comprise an areal density (AD) in a range of about 1.0 psf to about 3.0 psf. In some examples, the textile 109 and the backer 111 can be directly coupled to each other and extend around a perimeter of the metal strike face 103. Embodiments of the backer 111 also can comprise a textile having a thickness in a range of about 0.20 inches to about 0.60 inches.

Embodiments of the front and back covers 113, 115 can comprise at least one of polyurea, nylon or TPU. The front and back covers 113, 115 can comprise polyurea spray elastomer having, for example, a thickness of about 0.02 inches to about 0.25 inches.

Versions of the textile 109 can comprise the tensional wrap 151. The tensional wrap 151 can be coupled to the backer 111 to mitigate backface deformation of the metal strike plate 103 and edge shot capability of the armor assembly 101, in general. Portions 153 (FIGS. 5-10 ) of the tensional wrap 151 can overlap each other on the back of the metal strike plate 103. In some examples, the portions 153 can cover only a main body of a backside of the armor assembly 101 without covering side portions 155 of the backside. In one embodiment, the tensional wrap 151 can comprise portions 153 that are rectangular in shape and extend over the top and under the bottom of the armor assembly 101 to wrap around to the backside of the armor assembly 101. The armor assembly 101 can comprise a single curve.

In addition, the armor assembly 101 can further include perforations 405 (see, e.g., FIGS. 32-35 ) in the metal strike face 103 or any other layer, such as in a second strike face 403. The perforations 405 can be configured to cause a projectile fired at the armor to tumble.

Multi-Curve Armor

As noted above, FIGS. 11-14 show an embodiment of a multiple curve (e.g., five curve) armor assembly 201. FIGS. 15-24 depict an embodiment of the textile 209 as a tensional wrap 209 for fragmentation prevention, such as for the armor assembly 201. Armor assembly can share many features and elements with the other embodiments described herein. For example, armor assembly 201 can include a metal strike face 203, textile 209, backer 211, front cover 213, back cover 215 and structural adhesive 221. The textile 209 can comprise a tensional wrap. FIGS. 15-18 depict the tensional wrap 209 in an open configuration. FIG. 19 depicts the tensional wrap 209 in the process of being closed, and FIGS. 20-24 depict the tensional wrap in the closed configuration. In some versions, no portions of the tensional wrap 209 overlap each other on the back (see, e.g., FIG. 24 ) of the metal strike plate 203.

Integrally Pressed

As noted above, FIGS. 27-31 depict an embodiment of an integrally pressed armor assembly 301. Integrally pressing a layup of armor layers can comprise the process of sandwiching the fragmentation wrap, adhesive and strike face in polyethylene plies, then pressing them all together in a large press. The press can operate at a pressure in a range of about 1500 psi to about 20,000 psi (e.g., 6000 psi, or 1500 psi or more) and a temperature of not greater than about 300° F. (e.g., 260° F.), for example. This process can cause the polyethylene to totally encase the various layers into the hardened form that polyethylene takes after being pressed and cooled.

Armor assembly 301 can share many features and elements with the other embodiments described herein. For example, armor assembly 301 can include a metal strike face 303, textile 309, backer 311, front cover 313, back cover 315 and structural adhesive 321. The textile 309 may or may not comprise a tensional wrap. In some versions, the armor assembly 301 is integrally pressed and the backer 311 of the integrally pressed armor assembly 301 also can extend to the front (FIG. 30 ) of the metal strike face 303.

Other Examples

The different embodiments of the armor assembly can comprise an areal density in a range of about 3.2-10.2 psf. In a direction normal to an outer surface of the various embodiments of the armor assembly, the armor assembly can have a total thickness of about 0.35 inches to about 1.2 inches. In addition, examples of the armor assembly can have a total weight of not greater than about 8.0 pounds for Level III threats and 10.2 pounds for level IV threats. In some embodiments, versions of the armor assembly can consist of only one of each of the following: textile, metal strike face and backer. Examples of the armor assembly can be: worn on a torso or body part of a user, a helmet for the user, attached to a vehicle or installed in a building construction, such as for a safe room.

In other examples, an armor assembly can include a metal or alloy strike face having a front and a back. A textile can be coupled to the front of the alloy strike face with adhesive. A backer can be coupled to the back of the alloy strike face with the adhesive. In addition, a cover can be coupled to each of the textile and the backer with the adhesive.

In one example, the armor assembly can consist of only one of each of the following: textile, alloy strike face and backer. In other examples, the armor assembly can further include a second alloy strike face that is spaced apart from and coupled to the alloy strike face. Embodiments of the backer can be located between the alloy strike face and the second alloy strike face.

Different examples of the armor assembly can be configured to be worn on a torso of a user, a helmet for the user, attached to a vehicle, installed in a safe room construction, etc. Thus, the armor can comprise a flat panel, a single curve panel or a multi-curve panel. The multi-curve panel can include at least two curves, such as five different curved portions or surfaces.

Embodiments of the armor assembly can comprise an AD in a range of about range of about 3.2 psf to about 10.2 psf for both Level III and Level IV threats. The projectile ballistics or armor penetration levels as used herein, such as Level I, Level II, Level III and/or Level IV, refer to the industry standards disclosed at the National Institute of Justice (NIJ) 0101.06 and 0101.07.

In a direction normal to an outer surface of the armor assembly, the armor assembly can have a total thickness of about 0.35 inches to about 1.20 inches, in some versions for both Level III and Level IV threats.

Examples of the alloy strike face can be configured to stop penetration of a Level III or Level IV projectile through the alloy strike face. Versions of the alloy strike face can be configured to allow a Level III or a Level IV projectile to penetrate the alloy strike face and be stopped by the backer.

Embodiments of the alloy strike face can comprise at least one of an AISI 1050 to 1095 steel carbonitride, titanium, stainless steel, abrasion resistant steel, high carbon steel, ballistic metal or ballistic alloy. In a direction normal to the alloy strike face, the alloy strike face can comprise a thickness in a range of about 0.089 inches to about 0.5 inches, in some versions. In other versions, that thickness can be in a range of about 0.089 inches to about 0.119 inches, or about 0.115 inches to about 0.119 inches, or even up to about 0.125 inches. Alternatively, the alloy strike face comprises an abrasion metal resistance in a range of about 480 to about 2000 Vickers hardness (HV), or about 500 to about 1000 Vickers, or about 595 to about 674 Vickers.

Versions of the textile can include woven aramid, polyethylene, or like materials.

Examples of the adhesive can comprise a structural adhesive. In other examples, the armor assembly can include more than one type of adhesive. One of the adhesives can be a low energy bond, hi-strength acrylic adhesive. Versions of the adhesive can include a structural epoxy. The adhesive can have a thickness in a range of about 0.010 inches+/−0.01 inches.

Embodiments of the backer can include at least one of a textile, E-glass, R-glass, S-glass, polyethylene, polypropylene, polymer resin or aramid. The backer can be an ultra-high molecular weight polyethylene (UHMWPE). In one example, the backer may consist of Endumax® Shield XF33. Other versions of the backer can include a quantity of 1.5-3.0 psf of material.

Versions of the armor assembly can have the textile and the backer directly coupled to each other and extend around a perimeter of the alloy strike face. The armor assembly can further include a tensional wrap coupled to both the textile and the backer to mitigate backface deformation of the alloy strike plate and edge shot capability of the armor assembly. The wrap can form and hold tension across the strike plate. The wrap works well with a metal strike face comprising one or more plates, but the tension in the wrap may cause a traditional ceramic strike face to exhibit more cracks. In some versions of the single curve armor, the front is covered and wraps only along the top and bottom portions of the wrap, which extend to the rear of the armor, such that the sides are not wrapped. The top and bottom portions can overlap each other on the back of the armor. In contrast, the multi-curve armor can be entirely wrapped around its perimeter from the front to the rear, although the wrap portions may not overlap each other on the back of the armor.

The integrally pressed versions of the armor optionally has wrap, and its polyethylene content can fuse the layers together and act as fragmentation protection. The integrally pressed armor also can include adhesive on the front and back of the strike plate. An optional aramid layer also can be coupled to the front of the strike plate of the integrally pressed armor.

Embodiments of the cover can be located on the front and sides of the armor. A separate back cover may be located on the back of the armor, in some examples. Versions of the cover can be formed from hydrophobic nylon. The front and back covers can be connected, such as welded together with a heated tool, such as a hot knife.

Examples of the backer can include a textile having a thickness in a range of about 0.20 inches to about 0.60 inches, in some versions.

Embodiments of the cover can include at least one of polyurea, polyethylene, nylon or thermoplastic polyurethane (TPU). For example, the cover can comprise polyurea spray elastomer having a thickness of about 0.02 inches to about 0.125 inches. These materials can adhere to the other layers, sometimes without an adhesive.

The embodiments disclosed herein can include any, all or none of the features and materials listed below. For example, the total weight of the armor can be in a range of about 4 pounds to about 7 pounds. The armor can have a total thickness in a range of about 0.40 inches to about 1.20 inches. One strike plate option can include an alloy, such as HCS (1050-1095), which can have a thickness of about 0.089 inches to about 0.01 inches, with a Vickers hardness in one of the ranges described herein. Another strike plate option is a titanium alloy having a thickness in a range of about 0.115 inches to about 0.125 inches, or stainless steel with a thickness of about 0.089 inches to about 0.1 inches, or titanium with a thickness of about 0.089 inches to about 0.1 inches. One type of strike plate can include an abrasive resistant material with a thickness of about 0.115 inches to about 0.119 inches. Any of these embodiments can include any of the hardness ranges described herein. Structural adhesive options can include thermoplastic, thermosetting and/or elastomeric materials.

Fragmentation prevention options can include polyethylene, such as a ply or plies that match or are complementary to the cut of the strike plate; polyethylene, such as a ply or plies that partially or wholly wrap around some or all of the build layers to form and hold tension in the armor; aramid, such as a ply or plies that match the cut of the strike plate; and aramid, such as a ply or plies that partially or wholly wrap around some or all of the build layers to form and hold tension in the armor. The term “match the cut” can refer to the layers having the same shape and dimensions, so there is no overcut or undercut, nor any borders, such that the layers are flush on the edges.

Ballistic backer options can include UHMWPE, such as high pressure crystalized (HPC) formed at a range of about 1500 psi to about 10,000 psi (e.g., about 1500 psi to about 2000 psi), with an areal density of 1.0 to 4.0 psf; UHMWPE, such as MPC formed at 20 to 300 psi, with an areal density of 1.0 to 4.0 psf; and/or UHMWPE, such as LPC formed at 20 to 30 psi, with an areal density of 1.0 to 4.0 psf.

Backface reduction material options can include monolithic padding, a structured padding cover, polyurea, thermoplastic polyurethane and/or nylon.

In other examples, an armor assembly can include an alloy strike face having a front and a back. A textile can be coupled to the front of the alloy strike face with adhesive. A backer can be coupled to the back of the alloy strike face with the adhesive. In addition, a cover can be coupled to each of the textile and the backer with the adhesive.

In one example, the armor assembly can consist of only one of each of the following: textile, alloy strike face and backer. In other examples, the armor assembly can further include a second (or more) alloy strike face that is spaced apart from and coupled to the alloy strike face. Embodiments of the backer can be located between the alloy strike face and the second alloy strike face. Other embodiments can include perforations in the strike face or other layers that are designed to cause a projectile to tumble.

Different examples of the armor assembly can be configured to be applied in many different ballistic applications, worn on the torso of a user, a helmet for the user, a shield for a user, attached to a vehicle, installed in a safe room construction, etc.

Embodiments of the armor assembly can comprise a total aerial density (AD) weight in a range of about range of about 3.2 psf to about 10.2 psf for both level III and Level IV current NIJ rifle rated threats and common threats not listed in current NIJ standard (e.g., NIJ 0101.06).

In a direction normal to an outer surface of the armor assembly, the armor assembly can have a total thickness of about 0.35 inches to about 1.20 inches, in some versions for both level III and Level IV threats mentioned previously.

Examples of the alloy strike face can be configured to stop penetration of a Level III or IV projectile through the alloy strike face. Versions of the alloy strike face can be configured to allow a Level III or a Level IV projectile to penetrate the alloy strike face and be stopped by the backer.

Embodiments of the alloy strike face can comprise at least one of an AISI 1050 to 1095 treated steel, titanium, stainless steel, abrasive resistant steel, ballistic metal or ballistic alloy. In a direction normal to the alloy strike face, the alloy strike face can comprise a thickness in a range of about 0.089 inches to about 0.5 inches, in some versions. Alternatively, the alloy strike face comprises an abrasive metal resistance in any of the ranges described herein.

Versions of the textile can include woven aramid, polyethylene, or like materials.

Examples of the adhesive can comprise a structural adhesive. In other examples, the armor assembly can include more than one type of adhesive. One of the adhesives can be a low energy bond, high-strength acrylic adhesive. Versions of the adhesive can include a structural epoxy. The adhesive can have a thickness in a range of about 0.010 inches+/−0.01 inches.

Embodiments of the backer can include at least one of a textile, E-glass, R-glass, S-glass, polyethylene, polypropylene, polymer resin or aramid. The backer can be an ultra-high molecular weight polyethylene (UHMWPE). In one example, the backer may consist of Endumax® Shield XF33. Other versions of the backer can include a quantity of 1.0 to 3.0 psf of material.

Versions of the armor assembly can have the textile and the backer directly coupled to each other and extend around a perimeter of the alloy strike face. The armor assembly can further include a tensional wrap coupled to both the textile and the backer to mitigate backface deformation of the alloy strike face, overall durability of the build and edge shot capability of the armor assembly. Examples of the backer can include a textile having a thickness in a range of about 0.20 inches to about 1.00 inches.

Embodiments of the cover can include at least one of polyurea, polyurethane, rubber, resin, nylon or TPU. For example, the cover can comprise polyurea spray elastomer having a thickness of about 0.02 inches to about 0.125 inches.

Still other embodiments of the armor can include an alloy strike face, such as a heat treated AISI 1050 strike plate that can, in one example, be about 0.095 inches thick. An adhesive, such as 3M 300LSE adhesive, can bond to a front layer of textile (e.g., aramid), such as a 155D woven aramid lamination, and a rear layer backer, for example, Endumax SHIELD XF33. The backer can include a foam, such as EPE foam with adhesive that can be secured to the Endumax on the rear. A front layer of polyurea elastomer can be included on the aramid and the rear backer, in some versions. Optionally, a wrap can be used to cover the armor. The wrap can cover the entire front of the armor. In addition, elongated portions of the wrap (which can be rectangular in shape) can extend over the top and under the bottom of the armor to wrap around the rear of the armor on its backside. Examples can include the elongated portions covering only a main body of the backside without covering side portions of the backside of the armor. In one embodiment, the armor can have a total weight of about 4.5 pounds, a total thickness of about 0.62 inches, an areal density of about 6.2 psf, a curve angle of about 47° to about 49°, and a ballistic coverage of about 103 int.

Other embodiments can include one or more of the following items.

-   -   1. An armor assembly, comprising:         -   a metal strike face comprising a front and a back;         -   a textile coupled to the front of the metal strike face;         -   a backer coupled to the back of the metal strike face;         -   a front cover coupled to the textile;         -   a back cover coupled to the backer; and         -   the metal strike face is configured to allow a Level III or             a Level IV projectile to penetrate the metal strike face and             be stopped by the backer.     -   2. The armor assembly wherein the metal strike face comprises at         least one of heat-treated alloy, titanium, stainless steel,         abrasion resistant steel, ballistic metal or ballistic alloy.     -   3. The armor assembly wherein, in a direction normal to the         metal strike face, the metal strike face comprises a thickness         in a range of about 0.089 inches to about 0.5 inches.     -   4. The armor assembly wherein the metal strike face comprises an         abrasion metal resistance in a range of about 450 to about 2000         Vickers.     -   5. The armor assembly further comprising a structural adhesive         to bond at least one of metal strike face, textile, backer,         front cover and back cover.     -   6. The armor assembly wherein the structural adhesive comprises         structural epoxy having a thickness in a range of about 0.010         inches+/−0.01 inches.     -   7. The armor assembly wherein the structural adhesive comprises         more than one type of adhesive, and one of the adhesives         comprises a low energy bond, hi-strength acrylic adhesive.     -   8. The armor assembly wherein the armor assembly is integrally         pressed and the backer of the integrally pressed armor assembly         also extends to the front of the metal strike face.     -   9. The armor assembly wherein the armor assembly comprises an         areal density in a range of about 3.2 psf to about 10.2 psf     -   10. The armor assembly further comprising a second strike face         spaced apart from and coupled to the metal strike face.     -   11. The armor assembly wherein the second strike face comprises         at least one of a metal, an alloy or a ceramic.     -   12. The armor assembly wherein the backer is located between the         metal strike face and the second strike face.     -   13. The armor assembly wherein the metal strike face is         configured to stop penetration of a Level I or Level II or not         greater than Level IIIA projectile through the metal strike         face.     -   14. The armor assembly wherein the textile comprises at least         one of woven aramid or polyethylene.     -   15. The armor assembly wherein the backer comprises at least one         of a textile, E-glass, R-glass, S-glass, polyethylene,         polypropylene, polymer resin or aramid.     -   16. The armor assembly wherein the backer comprises an         ultra-high molecular weight polyethylene (UHMWPE).     -   17. The armor assembly wherein the backer comprises an areal         density in a range of about 1.0 psf to about 3.0 psf.     -   18. The armor assembly wherein the front and back covers         comprise at least one of polyurea, nylon or TPU.     -   19. The armor assembly wherein the front and back covers         comprise polyurea spray elastomer having a thickness of about         0.02 inches to about 0.25 inches.     -   20. The armor assembly wherein, in a direction normal to an         outer surface of the armor assembly, the armor assembly has a         total thickness of about 0.35 inches to about 1.2 inches.     -   21. The armor assembly wherein the armor assembly has a total         weight of not greater than about 8.0 pounds for Level Ill         threats and 10.2 pounds for level IV threats.     -   22. The armor assembly wherein the armor assembly consists of         only one of each of the following: textile, metal strike face,         front cover, back cover and backer.     -   23. The armor assembly wherein the armor assembly is configured         to be:         -   worn on a torso or body part of a user;         -   a helmet for the user;         -   attached to a vehicle or aircraft; or         -   installed in a building construction.     -   24. The armor assembly wherein the textile and the backer are         directly coupled to each other and extend around a perimeter of         the metal strike face.     -   25. The armor assembly further comprising a tensional wrap         coupled to both the textile and the backer to mitigate backface         deformation of the metal strike plate and edge shot capability         of the armor assembly.     -   26. The armor assembly wherein portions of the tensional wrap         overlap each other on the back of the metal strike plate.     -   27. The armor assembly wherein no portions of the tensional wrap         overlap each other on the back of the metal strike plate, and         the armor assembly comprises multiple curves.     -   28. The armor assembly wherein the tensional wrap comprises         elongated portions that are rectangular in shape and extend over         the top and under the bottom of the armor assembly to wrap         around a rear of the armor assembly, and the armor assembly         comprises a single curve.     -   29. The armor assembly wherein the elongated portions cover only         a main body of a backside without covering side portions of the         backside.     -   30. The armor assembly further comprising perforations in the         strike face or other layers that are configured to cause a         projectile to tumble.     -   31. The armor assembly wherein the backer comprises a textile         having a thickness in a range of about 0.20 inches to about 0.60         inches.     -   32. The armor assembly wherein the metal strike face is         configured to stop not greater than a Level IIIA projectile, and         the backer is configured to stop a Level Ill or Level IV         projectile.     -   33. The armor assembly further comprising a backface reduction         material coupled to the back of the metal strike face.

Still other versions can include one or more of the following items.

-   -   1. An armor assembly, comprising:         -   an alloy strike face comprising a front and a back;         -   a textile coupled to the front of the alloy strike face with             adhesive;         -   a backer coupled to the back of the alloy strike face with             the adhesive;         -   a cover coupled to each of the textile and the backer with             the adhesive; and         -   the alloy strike face is configured to allow a Level III or             a Level IV projectile to penetrate the alloy strike face and             be stopped by the backer.     -   2. The armor assembly wherein the alloy strike face comprises at         least one of a heat-treated alloy, titanium, stainless steel,         abrasive resistant steel, ballistic metal and ballistic alloy.     -   3. The armor assembly wherein, in a direction normal to the         alloy strike face, the alloy strike face comprises a thickness         in a range of about 0.089 inches to about 0.5 inches.     -   4. The armor assembly wherein the alloy strike face comprises an         abrasive metal resistance in any of the ranges disclosed herein.     -   5. The armor assembly wherein the adhesive comprises more than         one type of adhesive, and one of the adhesives comprises a low         energy bond, high-strength acrylic adhesive.     -   6. The armor assembly wherein the armor assembly comprises an         areal density in a range of about 3.2-10.2 psf.     -   7. The armor assembly further comprising a second strike face         spaced apart from and coupled to the alloy strike face.     -   8. The armor assembly wherein the second strike face comprises         at least one of an alloy and/or a ceramic.     -   9. The armor assembly wherein the backer is located between the         alloy strike face and the second strike face.     -   10. The armor assembly wherein the alloy strike face is         configured to stop penetration of not greater than a Level IIIA         projectile and the backer is configured to stop a Level III or a         Level IV projectile through the alloy strike face.     -   11. The armor assembly wherein the adhesive comprises structural         epoxy having a thickness in a range of about 0.010 inches+/−0.01         inches.     -   12. The armor assembly wherein the textile comprises at least         one of woven aramid or polyethylene.     -   13. The armor assembly wherein the backer comprises at least one         of a textile, E-glass, R-glass, S-glass, polyethylene,         polypropylene, polymer resin or aramid.     -   14. The armor assembly wherein the backer comprises an         ultra-high molecular weight polyethylene (UHMWPE).     -   15. The armor assembly wherein the backer comprises an areal         density in a range of about 1.0 psf to about 3.0 psf.     -   16. The armor assembly wherein the cover comprises at least one         of a polymer, polyurethane, polyurea, nylon or TPU.     -   17. The armor assembly wherein the cover comprises polyurea         spray elastomer having a thickness of about 0.02 inches to about         0.25 inches.     -   18. The armor assembly wherein, in a direction normal to an         outer surface of the armor assembly, the armor assembly has a         total thickness of about 0.35 inches to about 1.2 inches.     -   19. The armor assembly wherein the armor assembly has a total         weight of not greater than about 8.0 pounds for Level III         threats and 10.2 pounds for level IV threats.     -   20. The armor assembly wherein the armor assembly consists of         only one of each of the following: textile, alloy strike face,         front cover, back cover and backer.     -   21. The armor assembly wherein the armor assembly is configured         to be:         -   worn on a torso or body part of a user;         -   a helmet for the user;         -   attached to a vehicle, vessel or aircraft; or         -   installed in a building construction.     -   22. The armor assembly wherein the textile and the backer are         directly coupled to each other and extend around a perimeter of         the alloy strike face.     -   23. The armor assembly further comprising a tensional wrap         coupled to both the textile and the backer to mitigate backface         deformation of the alloy strike plate and edge shot capability         of the armor assembly.     -   24. The armor assembly wherein the backer comprises a textile         having a thickness in a range of about 0.20 inches to about 0.60         inches.     -   25. The armor assembly wherein the alloy strike face is         configured to augment a Level Ill or IV projectile and the         backer is configured to stop the Level III and or level IV         projectile.     -   26. The armor assembly wherein the cover comprises a wrap.     -   27. The armor assembly wherein the wrap covers an entire front         of the armor assembly.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” “top”, “bottom,” and the like, may be used herein for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated degrees or at other orientations) and the spatially relative descriptions used herein interpreted accordingly.

This written description uses examples to disclose the embodiments, including the best mode, and also to enable those of ordinary skill in the art to make and use the invention. The patentable scope is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

In the foregoing specification, the concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of invention.

It can be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The term “communicate,” as well as derivatives thereof, encompasses both direct and indirect communication. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrase “associated with,” as well as derivatives thereof, can mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items can be used, and only one item in the list can be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it states otherwise.

The description in the present application should not be read as implying that any particular element, step, or function is an essential or critical element that must be included in the claim scope. The scope of patented subject matter is defined only by the allowed claims. Moreover, none of the claims invokes 35 U.S.C. § 112(f) with respect to any of the appended claims or claim elements unless the exact words “means for” or “step for” are explicitly used in the particular claim, followed by a participle phrase identifying a function.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that can cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, sacrosanct or an essential feature of any or all the claims.

After reading the specification, skilled artisans will appreciate that certain features which are, for clarity, described herein in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, can also be provided separately or in any sub-combination. Further, references to values stated in ranges include each and every value within that range. 

We claim:
 1. An armor assembly, comprising: a metal strike face comprising a front and a back; a textile coupled to the front of the metal strike face; a backer coupled to the back of the metal strike face; a front cover coupled to the textile; a back cover coupled to the backer; and the metal strike face is configured to allow a Level III or a Level IV projectile to penetrate the metal strike face and be stopped by the backer.
 2. The armor assembly of claim 1, wherein the metal strike face comprises at least one of heat-treated alloy, titanium, stainless steel, abrasion resistant steel, ballistic metal or ballistic alloy.
 3. The armor assembly of claim 1 wherein, in a direction normal to the metal strike face, the metal strike face comprises a thickness in a range of about 0.089 inches to about 0.5 inches.
 4. The armor assembly of claim 1, wherein the metal strike face comprises an abrasion metal resistance in a range of about 500 to about 1000 Vickers.
 5. The armor assembly of claim 1, further comprising a structural adhesive to bond at least one of metal strike face, textile, backer, front cover and back cover.
 6. The armor assembly of claim 5, wherein the structural adhesive comprises structural epoxy having a thickness in a range of about 0.010 inches+/−0.01 inches.
 7. The armor assembly of claim 5, wherein the structural adhesive comprises more than one type of adhesive, and one of the adhesives comprises a low energy bond, hi-strength acrylic adhesive.
 8. The armor assembly of claim 1, wherein the armor assembly is integrally pressed and the backer of the integrally pressed armor assembly also extends to the front of the metal strike face.
 9. The armor assembly of claim 1, wherein the armor assembly comprises an areal density in a range of about 3.2 psf to about 10.2 psf
 10. The armor assembly of claim 1, further comprising a second strike face spaced apart from and coupled to the metal strike face.
 11. The armor assembly of claim 10, wherein the second strike face comprises at least one of a metal, an alloy or a ceramic.
 12. The armor assembly of claim 10, wherein the backer is located between the metal strike face and the second strike face.
 13. The armor assembly of claim 1, wherein the metal strike face is configured to stop penetration of a Level I or Level II projectile through the metal strike face.
 14. The armor assembly of claim 1, wherein the textile comprises at least one of woven aramid or polyethylene.
 15. The armor assembly of claim 1, wherein the backer comprises at least one of a textile, E-glass, R-glass, S-glass, polyethylene, polypropylene, polymer resin or aramid.
 16. The armor assembly of claim 1, wherein the backer comprises an ultra-high molecular weight polyethylene (UHMWPE).
 17. The armor assembly of claim 1, wherein the backer comprises an areal density in a range of about 1.0 psf to about 3.0 psf.
 18. The armor assembly of claim 1, wherein the front and back covers comprise at least one of polyurea, nylon or TPU.
 19. The armor assembly of claim 1, wherein the front and back covers comprise polyurea spray elastomer having a thickness of about 0.02 inches to about 0.25 inches.
 20. The armor assembly of claim 1 wherein, in a direction normal to an outer surface of the armor assembly, the armor assembly has a total thickness of about 0.35 inches to about 1.2 inches.
 21. The armor assembly of claim 1, wherein the armor assembly has a total weight of not greater than about 8.0 pounds for Level III threats and 10.2 pounds for level IV threats.
 22. The armor assembly of claim 1, wherein the armor assembly consists of only one of each of the following: textile, metal strike face, front cover, back cover and backer.
 23. The armor assembly of claim 1, wherein the armor assembly is configured to be: worn on a torso or body part of a user; a helmet for the user; attached to a vehicle, vessel or aircraft; or installed in a building construction.
 24. The armor assembly of claim 1, wherein the textile and the backer are directly coupled to each other and extend around a perimeter of the metal strike face.
 25. The armor assembly of claim 1, further comprising a tensional wrap coupled to both the textile and the backer to mitigate backface deformation of the metal strike plate and edge shot capability of the armor assembly.
 26. The armor assembly of claim 25, wherein portions of the tensional wrap overlap each other on the back of the metal strike plate.
 27. The armor assembly of claim 25, wherein no portions of the tensional wrap overlap each other on the back of the metal strike plate, and the armor assembly comprises multiple curves.
 28. The armor assembly of claim 25, wherein the tensional wrap comprises elongated portions that are rectangular in shape and extend over the top and under the bottom of the armor assembly to wrap around a rear of the armor assembly, and the armor assembly comprises a single curve.
 29. The armor assembly of claim 28, wherein the elongated portions cover only a main body of a backside without covering side portions of the backside.
 30. The armor assembly of claim 1, further comprising perforations in the strike face or other layers that are configured to cause a projectile to tumble.
 31. The armor assembly of claim 1, wherein the backer comprises a textile having a thickness in a range of about 0.20 inches to about 0.60 inches.
 32. The armor assembly of claim 1, wherein the metal strike face is configured to augment a Level III or IV projectile and the backer stops the Level III and or level IV projectile.
 33. The armor assembly of claim 1, further comprising a backface reduction material coupled to the back of the metal strike face. 